Electrodes For Electronic Weaponry And Methods Of Manufacture

ABSTRACT

A deployment unit for an electronic control device (ECD) used as a weapon provides a current from a signal generator of the ECD through tissue of a human or animal target. The deployment unit includes a housing, an interface, a filament, and an electrode. The interface couples the housing to the signal generator. The filament includes a first end coupled to the interface for receiving the current and comprises a second end. The filament conducts the current for inhibiting voluntary movement by the target. The electrode, stored in the housing prior to deployment, mechanically couples the filament to the target when deployed. The electrode includes an assembly of a first part and a second part that after assembly cooperate to bind the second end of the filament to the electrode.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of and claims priority under 35U.S.C. §120 from co-pending U.S. patent application Ser. No. 12/983,163to Beechey, filed Dec. 31, 2010.

FIELD OF THE INVENTION

Embodiments of the present invention relate to electronic weaponry,electronic control devices, deployment units for electronic weaponry,electrodes used in deployment units, and methods of manufacturing suchelectrodes that provide a current through a human or animal target.

BACKGROUND OF THE INVENTION

Conventional electronic control devices (ECDs) include hand-heldlaunchers that launch one or more probes, also called darts, to strike ahuman or animal target. In one implementation, a current sourced by thelauncher is conducted through the probe. A tether wire conducts thecurrent from a signal generator in the launcher to the probe. Thecircuit or path through the target includes the signal generator, one ormore tether wires and one or more probes.

Conventional techniques to attach the tether wire to the probe mayinvolve a considerable amount of manual labor and/or subject the tetherwire to stress that may cause the wire to break immediately or break inuse due to the stress of propelling the probe to the target.

Improved techniques to attach the tether wire to the probe aredesirable, for example, to improve reliability.

BRIEF DESCRIPTION OF THE DRAWING

Embodiments of the present invention will now be further described withreference to the drawing, wherein like designations denote likeelements, and:

FIG. 1 is a functional block diagram of an electronic weapon accordingto various aspects of the present invention;

FIG. 2 is a functional block diagram of a circuit that includes a targetand an electrode of the electronic weapon of FIG. 1;

FIG. 3A is a functional block diagram of an electrode of the electronicweapon of FIG. 1;

FIG. 3B is a functional block diagram of another electrode for theelectronic weapon of FIG. 1;

FIG. 3C is a functional block diagram of still another electrode for theelectronic weapon of FIG. 1;

FIG. 4 is a side plan view of an implementation of the electronic weaponof FIG. 1 a moment after the launch of two electrodes according to anyof FIGS. 3A, 3B, and 3C;

FIG. 5 is a cross-section view of the deployment unit of the electronicweapon of FIG. 4;

FIG. 6 is a cross-section view of an electrode in an implementationaccording to FIG. 3A;

FIG. 7 is a view of the rear face of the electrode of FIG. 6;

FIG. 8 is a perspective view of an electrode in another implementationaccording to FIG. 3B;

FIG. 9 is a perspective view of the rear portion of the electrode ofFIG. 8;

FIG. 10 is a perspective view of an electrode in still anotherimplementation according to FIG. 3C;

FIG. 11 is a cross-section view of the electrode of FIG. 10;

FIG. 12 is a perspective view of a portion of the electrode of FIG. 10,fully assembled;

FIG. 13 is a perspective view of a front portion of the electrode ofFIG. 10 prior to completing assembly; and

FIG. 14 is a perspective view of a rear portion of the electrode of FIG.10 as seen prior to assembly onto the front portion of FIG. 13.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

An electronic weapon, according to various aspects of the presentinvention, delivers a current through a human or animal target tointerfere with locomotion by the target. An important class ofelectronic weapons launch at least one tethered electrode (e.g., dart,probe) toward a target to position the electrode in or near targettissue. A respective filament (e.g., wire with or without insulation)extends from the electronic weapon to each electrode at the target,thereby tethering the electrode to the electronic weapon. One or moreelectrodes may form a circuit through a target. The circuit conducts thestimulus signal. The circuit's return path may be through ground,through one or more additional tethered electrodes, or through aconductive path (e.g., liquid, plasma) formed by the electronic weaponto the target. The electronic weapon provides a stimulus signal (e.g.,current, pulses of current) through, inter alia, the filament, theelectrode, and the target to interfere with locomotion by the target.Interference includes causing involuntary contraction of skeletalmuscles to halt voluntary locomotion by the target and/or causing painto the target to motivate the target to voluntarily stop moving.

Conventional stimulus signals may be used. For example, a stimulussignal may comprise about 19 current pulses per second at a duty cycleless than 1/400, repeated for a period of from 5 to 30 seconds tofacilitate arrest of the target or escape from the target.

An electronic weapon, according to various aspects of the presentinvention, may include a launch device and one or more field replaceabledeployment units mounted to the electronic weapon. Each deployment unitmay include expendable (e.g., single use) components (e.g., tetherwires, electrodes, propellant), and storage cavities (e.g., bores,chambers).

A tethered electrode is an assembly of a filament (e.g., cord, wire,conductor, group of cords and/or conductors) and an electrode at leastmechanically coupled to an end portion of the filament. A portion of thefilament near the other end of the filament is at least mechanicallycoupled to the deployment unit and/or the launch device (e.g., one endfixed within the deployment unit), generally until the deployment unitis removed from the electronic weapon. As discussed below, mechanicalcoupling may facilitate electrical coupling of the launch device and theelectrode prior to and/or during operation of the electronic weapon.

A launch device of an electronic weapon launches at least one tetheredelectrode of the electronic weapon toward a target. As the electrodetravels toward the target, the electrode deploys (e.g., pulls) a lengthof filament from storage within the deployment unit. The filament trailsthe electrode. After launch, the filament spans (e.g., extends, bridges,stretches) a distance from the deployment unit to the electrode that isgenerally positioned in or near a target.

Electronic weapons that use tethered electrodes, according to variousaspects of the present invention, include hand-held devices, apparatusfixed to buildings or vehicles, and stand-alone stations. Hand-helddevices may be used in law enforcement, for example, deployed by anofficer to take custody of a target. Apparatus fixed to buildings orvehicles may be used at security checkpoints or borders, for example, tomanually or automatically acquire, track, and/or deploy electrodes tostop intruders. Stand-alone stations may be set up for area denial, forexample, as used by military operations. Conventional electronic weaponssuch as the model X26 electronic control device and Shockwave™ areadenial unit, each marketed by TASER International, Inc., may be modifiedto implement the teachings of the present invention by replacing theconventional deployment units with deployment units having electrodes asdiscussed herein.

An electrode, according to various aspects of the present invention,provides a mass for launching toward a target. The intrinsic mass of anelectrode includes a mass that is sufficient to fly, under force of apropellant, from a launch device to a target. The mass of the electrodeincludes a mass that is sufficient to deploy (e.g., pull, uncoil,unravel, draw) a filament from storage and/or pay out a filament fromstorage on or in the electrode. The mass of the electrode is sufficientto deploy a filament behind the electrode while the electrode fliestoward a target. The mass of the electrode deploys the filament fromstorage and behind the electrode in such a manner that the filamentspans a distance between the launch device and the electrode positionedat a target. The mass of an electrode is generally insufficient to causeserious blunt impact trauma to a target. In one implementation, the massof an electrode that draws a filament from storage in a deployment unitis in the range of 2 to 3 grams, preferably about 2.8 grams.

An electrode provides a surface area for receiving a propelling force topropel the electrode away from a launch device and toward a target.Movement of the electrode away from the launch device is limited byaerodynamic drag and by a resistance force (e.g., tension in thefilament) that resists deploying a filament from storage and pulling thefilament behind the electrode in flight toward a target.

A forward portion of an electrode may be oriented toward a target priorto launch. Upon launch and/or during flight from the launch devicetoward the target, the forward portion of the electrode may orienttoward the target. An electrode may have an aerodynamic form formaintaining the forward portion of the electrode oriented toward atarget. The aerodynamic form of an electrode provides suitable accuracyfor hitting the target.

An electrode includes a shape for receiving a propelling force to propelthe electrode toward a target. A shape of an electrode may correspond toa shape of a portion of the launch device or deployment unit thatprovides a propelling force to propel the electrode. For example, acylindrical electrode may be propelled from a cylindrical tube of adeployment unit. During a launch of an electrode by expanding gas, theelectrode may seal the tube to accomplish suitable acceleration andmuzzle velocity. A rear face of the cylindrical electrode may receivesubstantially all of the propelling force.

An electrode may include a substantially cylindrical overall shape.Prior to launch, such an electrode is positioned in a substantiallycylindrical tube slightly larger in diameter than the electrode. Apropelling force (e.g., rapidly expanding gas) is applied to a closedend of the tube. The force pushes against a rear portion of theelectrode to propel the electrode out of an open end of the tube towarda target.

An electrode includes a shape and a surface area for aerodynamic flightfor suitable accuracy of delivery of the electrode across a distancetoward a target, for example, about 15 to 35 feet from a launch deviceto a target. An electrode may rotate in-flight to provide spinstabilized flight. An electrode may maintain its pre-launch orientationtoward a target during launch, flight to, and impact with a target.

An electrode or major portion of an electrode may have a conical orfrustoconical shape (e.g., cone, golf tee, series of axially nestedcones) with the base of the shape receiving the propelling force.

On impact, an electrode mechanically couples to a target. Mechanicalcoupling includes penetrating target clothing and/or tissue, resistingremoval from clothing and/or tissue, remaining in contact with a targetsurface (e.g., tissue, hair, clothing, armor), and/or resisting removalfrom the target surface. Coupling may be accomplished by piercing,lodging (e.g., hooking, grasping, entangling, adhering, gluing), and/orwrapping (e.g., encircling, covering). An electrode, according tovarious aspects of the present invention, includes structure (e.g.,hook, barb, spear, glue ampoule, tentacle, bolo) for mechanicallycoupling the electrode to a target. A structure for coupling maypenetrate a protective barrier (e.g., clothing, hair, armor) on an outersurface of a target.

An electrode may include an integral structure or separate partfunctioning as a spear (e.g., pointed shaft, needle). The spearpenetrates target clothing and/or tissue up to the length of the spear(e.g. up to a face of the electrode). Penetration is arrested byfriction (e.g., contact of the spear with target clothing or tissue,abutment of a face of the electrode and the target). A spear may extendaway from a face of the electrode toward the target. The spear mayinclude one or more barbs for increasing the strength of the mechanicalcoupling of the electrode to the target. The barbs may be arranged toaccomplish suitable mechanical coupling at various lengths ofpenetration of clothing and/or tissue.

An electrode is mechanically coupled to a filament to deploy thefilament from storage and to extend the filament from the launch deviceto the target. Mechanical coupling includes coupling a filament and anelectrode with sufficient strength to retain the coupling duringmanufacture, prior to launch, during launch, after launch, duringmechanical coupling of the electrode to a target, and while delivering astimulus signal to a target. Mechanical coupling may be accomplished byconfining the filament between surfaces of an electrode and/or confiningthe filament within a portion of the electrode (e.g., establishing asuitable stiction between a portion of the filament and one or moresurfaces of an electrode). Confining may include enclosing, holding,retaining, maintaining mechanical coupling, and/or resisting separation.Confining may be accomplished by preventing or resisting movement ordeformation (e.g., stretching, twisting, bending) of the filament. Asdiscussed below, placing the filament in an interior and affixing aspear over the interior in one implementation confines the filament tothe interior.

An electrode facilitates electrical coupling of the launch device andthe target. Electrical coupling generally includes a region or volume oftarget tissue associated with the electrode (e.g., a respective regionfor each electrode when more than one electrode is used). According tovarious aspects of the present invention, one or more structures of theelectrode accomplish lower current density in the region or volumecompared to prior art electrodes.

For each electrode, electrical coupling may include placing theelectrode in contact with target tissue (e.g. touching, inserting)and/or ionizing air in one or more gaps between the launch device, thedeployment unit, the filament, the electrode, and target tissue. Forexample, a placement of an electrode with respect to a target thatresults in a gap of air between the electrode and the target does notelectrically couple the electrode to the target until ionization of theair in the gap. Ionization may be accomplished by a stimulus signal thatincludes, at least initially, a relatively high voltage (e.g., about25,000 volts for one or more gaps having a total length of about oneinch). After initial ionization, the electrode remains electricallycoupled to the target while the stimulus signal supplies sufficientcurrent and/or voltage to maintain ionization. Ionization may not beneeded, for instance when contact is accomplished by spreading involvingdirect conduction from a filament to the target.

Assembly of a tethered electrode, according to various aspects of thepresent invention, is reliably accomplished in less time and with fewerand/or different operations than employed by prior art techniques.Manufacturing cost savings may result.

An electrode for use with a deployment unit and/or an electronic weapon,according to various aspects of the present invention, performs thefunctions discussed above. For example, any of electrodes 142, 143, 600,800, and 1000 of FIGS. 1-14 may be launched from weapon 100 toward atarget to establish a circuit with the target to provide a stimulussignal through the target.

Electronic weapon 100 of FIG. 1 includes launch device 110 anddeployment unit 130. Launch device 110 includes user controls 112,processing circuit 114, power supply 116, and signal generator 118. Inone implementation, launch device 110 is packaged in a housing. Thehousing may include a mechanical and electrical interface for adeployment unit 130. Conventional electronic circuits, processingcircuit programming, propulsion technologies, and mechanicaltechnologies may be used, suitably modified, and/or supplemented asdiscussed herein.

A user control is operated by a user to initiate an operation of theweapon. User controls 112 may include a trigger, a manual safety, and/ora touch screen user interface operated by a user. When user controls 112are packaged separately from launch device 110, any conventional wiredor wireless communication technology may be used to link user controls112 with processing circuit 114.

A processing circuit controls many if not all of the functions of anelectronic weapon. A processing circuit may initiate a launch of one ormore electrodes responsive to a user control. A processing circuit maycontrol an operation of a signal generator to provide a stimulus signal.For example, processing circuit 114 receives a signal from user controls112 indicating user operation of the weapon to launch an electrode andprovide a stimulus signal. Processing circuit 114 provides a launchsignal 152 to deployment unit 130 to initiate launch of one or moreelectrodes. Processing circuit 114 may provide a signal to signalgenerator 118 to provide the stimulus signal to the launched electrodes.Processing circuit 114 may include a conventional microprocessor andmemory that executes instructions (e.g., processor programming) storedin memory.

A power supply provides energy to operate an electronic weapon and toprovide a stimulus signal. For example, power supply 116 provides energy(e.g., current, pulses of current) to signal generator 118 to provide astimulus signal. Power supply 116 may further provide power to operateprocessing circuit 114 and user controls 112. For hand held electronicweapons, a power supply generally includes a battery.

A signal generator provides a stimulus signal for delivery through atarget. A signal generator may reform energy provided by a power supplyto provide a stimulus signal having suitable characteristics (e.g.,ionizing voltage, charge delivery voltage, charge per pulse of current,current pulse repetition rate) to interfere with target locomotion. Asignal generator electrically couples to a filament to provide thestimulus signal through the target as discussed above. For example,signal generator 118 provides a stimulus signal to tethered electrodes142-143 of deployment unit 130 via their respective filaments 140-141.Signal generator 118 is electrically coupled via stimulus interface 150to filaments stored in deployment unit 130. The stimulus signal mayconsist of from 5 to 40 pulses per second, each pulse capable ofionizing air, each pulse delivering after ionization (if needed) about80 microcoulombs of charge through a human or animal target having animpedance of about 400 ohms.

A deployment unit (e.g., cartridge, magazine) receives a launch signalfrom a launch device to initiate a launch of one or more electrodes anda stimulus signal to deliver through a target. A spent deployment unitmay be replaced with an unused deployment unit after some or allelectrodes of the spent deployment unit have been launched. An unuseddeployment unit may be coupled to the launch device to enable additionalelectrodes to be launched. A deployment unit may receive, via aninterface, signals from a launch device to perform the functions of adeployment unit.

For example, deployment unit 130 may include one or more cartridges132-134. Each cartridge 132 (134) may include one or more filaments 140(141), one or more electrodes 142 (143), and one or more propellants 144(145). A deployment unit stores a filament for each electrode or groupof electrodes. Each filament mechanically couples to an electrode orgroup of electrodes as discussed herein. Via launch signal 152,processing circuit 114 initiates activation of propellant 144 (145) forone or more selected cartridges. Propellant 144 (145) propels one ormore electrodes 142 (143) toward a target. Each electrode is coupled todeploy a respective filament from storage. As each electrode fliestoward the target, each electrode deploys its respective filament outfrom its storage. Signal generator 118 provides the stimulus signalthrough the target via stimulus interface 150 and the filaments coupledto launched electrodes 142 (143).

Each propellant may serve to launch any number of electrodes. Forinstance, a deployment unit formed as a replaceable cartridge mayinclude a housing, an electrical interface, two electrodes, onepropellant for launching the two electrodes, and two filaments, one foreach electrode.

An electrode, according to various aspects of the present invention, mayperform one or more of the following functions in any combination:binding the filament to the electrode, deploying the filament,mechanically coupling the electrode to a target, enabling conduction ofthe stimulus current from the filament through the target, spreading acurrent density with respect to a region of target tissue, and diffusinga current into a volume of target tissue. Enabling conduction includesionizing, spreading, and/or diffusing. Enabling conduction, may includeionization along or through insulative and/or composite material of oneor more portions of the electrode. Enabling conduction may includeionization along or through insulative and/or composite materialexternal to the electrode. Insulative materials include any material orsubstance (e.g., gas, liquid, solid, aggregation, suspension, composite,alloy, mixture) that presents, at any time or times, a relatively highresistance to current of the stimulus signal. Composite materialsinclude insulative materials combined with conductive particles, layers,or fibers.

In operation with a target, an electrode conducts current in a circuitthat includes the target and a signal generator. For example, circuit200 of FIG. 2 includes filament 140, electrode 142, target tissue 202,and return path 204. Return path 204 in one implementation includes aconductor common to the signal generator and the target (e.g., earth).The return path in another implementation, not shown, includes a secondtethered electrode (e.g., 134). Current of any conventional polarity orpolarities may flow in one or more directions on any of the lines shownin FIG. 2 at various times.

An electrode has mass, shape, and surfaces for being attached to afilament, for being propelled, and for deploying the filament to atarget, as discussed above. Conventional mass, shape, and surfaces maybe employed. For example, an electrode may have a substantiallycylindrical shape, an interior with surfaces that abut and/or grip afilament, and external surfaces with suitable aerodynamic properties forefficient propulsion and accurate flight to a target. An electrode mayemploy conductive, resistive, composite and/or insulative material on anintended path of conduction or propagation of stimulus current. Anelectrode may employ resistive, insulative, and/or composite material todiminish stimulus current conduction on undesired paths. An electrodemay be rigid. To avoid breaking on impact, an electrode may haveportions designed to flex to absorb energy of impact and thereby reducethe risk of breakage. Conventional metal and/or plastic fabricationtechnologies may be used in the manufacture of an electrode as discussedherein. Plastics may be filled with other materials (e.g., conductiveparticles, fibers, layers) to form composite materials uniformly or insuitable portions of a part.

An electrode may have any size and shape known in the art for suitablybinding a filament and deploying a filament (e.g., substantiallyspherical, substantially cylindrical, having an axis of symmetry in thedirection of flight, bullet shaped, tear drop shaped, substantiallyconical, golf tee shaped). In various implementations, an electrode maybe formed of conductive, resistive, insulative, and/or compositematerials, as discussed above. If insulative, a body portion of anelectrode (i.e., all structures except those functioning as a spear,target retainer, or tip) may comprise composite material and/or becoated with insulative material.

A spear may perform mechanical coupling and/or be activated as discussedabove. A spear may have any size and shape known in the art for suitablypiercing material and/or tissue of a target, lodging in material and/ortissue of a target, and forming an ionized path from the tip of thespear to target tissue. In various implementations, a spear may beformed of conductive, resistive, insulative, and/or composite materials.A spear may be partially or entirely formed of a material thatelectrically insulates. When insulative, the electrode may comprisecomposite material and/or be coated with insulative material. Activationand use of a shaft and/or tip may reform paths along and/or through theinsulative or composite material.

An insulator may be of a type (e.g., thickness, material, structure)that electrically insulates the spear against a current having a voltagebelow a threshold, but fails to insulate the spear against a currenthaving a voltage above the threshold. An insulator may be formed (e.g.,shaped, applied, positioned, removed, partially removed, cut) toestablish a likely location on the spear where the insulator may fail toinsulate against a current having a voltage above a threshold. Aninsulator may define a series of gaps between conductors of the spear orconductive portions of the spear. The gaps may act as switches operativeto conduct in response to the applied voltage of the stimulus signal.

A tip (e.g., point, cone, apex comprising acute angles between faces,end of a shaft of relatively small diameter) operates to pierce an outersurface (e.g., layer) of a target and/or target tissue. A tip of a spearfacilitates mechanical coupling by piercing and lodging. A tip wheninsulated may operate as a gap or switch interfering with current flow(e.g., blocking) until a threshold voltage breaks down the insulatorand/or permits ionization near the tip followed by current flow throughthe tip.

A barb operates to lodge (e.g., retain) an electrode in clothing, armor,and/or tissue of a target to retain a mechanical coupling between thebarb and the target. A barb portion of a spear resists mechanicaldecoupling (e.g. separation or removal from the target). A spear mayinclude a barb near the tip. A spear may include a plurality of barbsarranged at increasing distance from the tip. A barb may include acontinuous surface of the spear (e.g., a helical channel or ridge, ascrew thread or channel, a surface having an undulation that increasesfriction between the barb and the target.

According to various aspects of the present invention, an electrode maycomprise several structures that are coupled together to completeassembly of the electrode. These structures, when independent objects,are herein called parts, as opposed to portions of the same object.Receiving and conducting the stimulus signal is herein calledactivation.

A functional block diagram of an electrode, according to various aspectsof the present invention, illustrates functional and structuralcooperation. A carrying part and a piercing part may be mechanicallycoupled together. A carrying part carries a filament and/or retains afilament. A piercing part pierces clothing and/or tissue of a target tomechanically couple an electrode to a target. As shown in FIG. 3A,electrode 142 performs mechanical and electrical functions discussedabove. Electrode 142 of FIG. 3A may be activated via filament 140 (notshown) with current to and/or from signal generator 118. Electrode 142may be activated with current to and/or from target tissue 202 (notshown). Currents may pass via one or more paths through electrode 142and via one or more paths through target tissue 202.

Electrode 142 of FIG. 3A includes carrying part 302 and piercing part304. Carrying part 302 includes x-fastener 312, filament retainer 314,and shaft positioner 316. Piercing part 304 includes y-fastener 322,filament positioner 324, and spear 306. Spear 306 includes shaft 332,target retainer 334, and tip 336. The total mass of electrode 142 may bedistributed between carrying part 302 and piercing part 304 toaccomplish desired deployment behavior and target retaining behavior.Conventional ballistics analysis techniques may be used.

A carrying part mechanically couples to a piercing part. For example,carrying part 302 includes x-fastener 312. Piercing part 304 includesy-fastener 322. The x-fastener 312 and y-fastener 322 represent matingfasteners of conventional technologies. Any fastening technology may beused (e.g., threading, snapping, hook and loop, friction fit, bayonet,latching). According to various aspects of the present invention, x- andy-fasteners may comprise surfaces suitable for any joining technology(e.g., gluing, welding, sonic welding).

Carrying part 302 includes filament retainer 314. Filament retainer 314mechanically retains the filament to enable electrode 142 to deploy thefilament when electrode 142 is deployed. Retention may include anyfastening technology (e.g., screw threads, bayonet type, snap, latch),binding technology (e.g., friction fitting, staking), and/or joiningtechnology (e.g., sonic welding, adhesives), for example, as discussedabove, that is suitable for reliably securing a filament to the carryingpart. Binding by friction facilitates relatively low manufacturing cost,mechanical reliability, and ease of manual and/or automated assembly ofelectrode 142. One end of a filament may be retained (e.g., fixed inplace) to carrying part 302 by filament retainer 314 before assemblingfastening part 302 with piercing part 304.

X-fastener 312 and y-fastener 322, according to various aspects of thepresent invention, may cooperate with the filament retainer 314 toaccomplish retention. For example, compression required to assemble x-and y-fasteners to each other and/or resulting from fastening may exerta force that increases friction for suitable binding.

A carrying part may partially enclose a piercing part. In anotherimplementation, a piercing part may partially enclose a carrying part.According to various aspects of the present invention, particularsynergies are realized in an electrode 142 that is assembled bycombining carrying part 302 and piercing part 304 on an axis. Forexample, when x-fastener 312 has a first axis and y-fastener 322 has asecond axis, these fasteners may be aligned to an alignment axis andthen moved together along the alignment axis to accomplish assembly ofthe two parts.

Carrying part 302 may further include one or more structural featuresthat position a shaft of a spear. Shaft positioner 316 securelymaintains a position of spear 306 with respect to a front face ofelectrode 142. Shaft positioner 316 may retain shaft 332 at a particularlength extending away from the front face. Shaft positioner 316 may becapable of retaining shaft 332 at one of a set of fixed lengths selectedduring assembly of electrode 142. By permitting selection duringassembly, different electrode designs may be manufactured from partsthat are common to all designs (e.g., same carrying part, same spear).

A front face of an electrode resists further penetration of electrode142 into a target. A front face having dimensions larger than thediameter of shaft 332 stops penetration of shaft 332 by abutting targetclothing or tissue 202. Consequently, a shaft positioner whenimplemented with a front face may determine a maximum depth ofpenetration of an electrode into a target.

Carrying part 302 may be implemented as an integral monolithic structureformed of one material. Forming may include molding, casting, extruding,and/or milling. When carrying part 302 is desired to be non-insulative(conductive, resistive, or subject to ionization along or through afteran activation voltage is exceeded), conductive filler may be included inthe material used to form carrying part 302.

A piercing part pierces clothing or target tissue to form and tomechanically maintain the electrical circuit discussed with reference toFIG. 2. A piercing part may retain a filament as discussed above and mayelectrically couple a filament to the target by positioning the filamentproximate to the target. A piercing part may be implemented as anintegral monolithic structure formed of one material. A piercing partmay include a spear as a separate part that is combined to form thecomplete piercing part.

For example, piercing part 304 performs the functions of an electrodediscussed above in cooperation with carrying part 302. Y-fastener 322establishes and secures the assembly of the carrying part 302 andpiercing part 304 through the mechanical stresses of launching, filamentdeployment, and electrode impact with a target. Filament positioner 324maintains the filament in relation to piercing part 304 and therebymaintains the filament in relation to target tissue. A spear performsthe piercing function of a piercing part of an electrode. A spear mayalso perform a retaining function to mechanically retain the electrodein contact with the target (e.g., by maintaining a relative position ofthe piercing part with respect to the target).

For example, spear 306 includes shaft 332, target retainer 334, and tip336. A shaft supports a target retainer and a tip. A shaft and tipcooperate to accomplish piercing to a desired depth. The shaft isgenerally suitable for penetration of clothing and/or target tissue. Thelength of the shaft may locate the tip a desired distance from a frontface of the electrode, as discussed above, so that only the shaft andtip penetrate target clothing and/or tissue when the face abuts thetarget. The shaft may flex a suitable amount on impact to avoidbreakage.

A target retainer resists removal of the shaft from the target. A targetretainer may be implemented with one or more barbs arranged behind thetip.

A tip includes any structure that pierces target clothing and/or tissue.A tip may include one or more points front-facing toward the target. Atip may be formed with a target retainer immediately behind the tip(e.g., barb, rear-facing point).

The total mass of electrode 142 of FIG. 3B may be distributed betweenaft part 342 and fore part 344 to accomplish desired deployment behaviorand target retaining behavior. Conventional ballistics analysistechniques may be used.

Another functional block diagram of an electrode, according to variousaspects of the present invention, illustrates somewhat differentfunctional and structural cooperation. Electrode 142 of FIG. 3B includesaft part 342 and fore part 344. Aft part 342 includes x-fastener 350 andx-filament retainer 352. Fore part 344 includes y-fastener 354,y-filament retainer 356, and spear 358. In implementations according tothis functional block diagram, electrode 142 performs the functionsdiscussed above. Electrode 142 is assembled by mating x-fastener 350with y-fastener 354 where x-fastener 350 and y-fastener 354 may includethe structures and functions discussed above with reference tox-fastener 312 and y-fastener 322.

The function of retaining a filament, as discussed above, is performedby x- and y-filament retainers 352 and 354 when assembly of electrode142 is completed. In one implementation, x- and y-filament retainersbind a filament when abutted against each other. Any conventionaltwo-part retention technology may be used (e.g., fastening, binding,joining) between an end of a filament, x-filament retainer, andy-filament retainer.

X-fastener 350 and y-fastener 354 may cooperate with x-filament retainer352 and y-filament retainer 354 to distribute strain occurring betweenelectrode 142 and a filament. Distributing strain may facilitate usingsmaller, lighter, and/or weaker technologies for these functionsindividually.

Spear 358 may include the structures and perform the functions discussedabove with reference to spear 306. In the absence of the need tocooperate with a shaft positioner, spear 358 may be structurally simplerthan spear 306. Spear 358 may be integral to fore part 344 (e.g., formedof the same material and/or formed at the same time). Spear 358 may befixed to fore part 344 prior to assembly of aft and fore parts 342 and344.

According to various aspects of the present invention, electrode 142 ofFIG. 3B may be assembled by combining aft part 342 and fore part 344 onan axis. For example, when x-fastener 350 has a first axis andy-fastener 354 has a second axis, these fasteners may be aligned to analignment axis and then moved together along the alignment axis toaccomplish assembly of the two parts.

Another functional block diagram of an electrode, according to variousaspects of the present invention, illustrates somewhat differentfunctional and structural cooperation. Electrode 142 of FIG. 3C includesaft part 362 and fore part 364. Aft part 362 includes x-filamentretainer 370 that also serves to retain aft part 362 and fore part 364in an assembled configuration. Fore part 364 includes y-filamentretainer 372, mass 374, target retainer 376, and tip 378.

In implementations according to the functional block diagram of FIG. 3C,electrode 142 performs the functions discussed above. Electrode 142 isassembled by mating x-filament retainer 370 with y-filament retainer372. X-filament retainer 370 and y-filament retainer 372 may include thestructures and functions discussed above with reference to x-fastener350, y-fastener 354, x-filament retainer 352, and y-filament retainer356, suitably designed to accomplish fastening and filament retainingwithout distribution of strain as discussed above with reference to FIG.3B.

Fore part 364 may include substantially all of the mass of electrode 142(e.g., greater than 80%, about 90%) Such a mass distribution may inhibittumbling of electrode 142 during launching, deployment, and/or impactinga target. For example, mass 374 may comprise a material of greaterdensity than materials of other portions of fore part 364. In one classof implementations, mass 374 comprises a plastic carrier impregnatedwith particles and/or fibers of denser material (e.g., metal, carbon,graphite, brass, stainless steel). Mass 374 may be formed on or about ashaft portion of fore part 364. A front face, as discussed above, forfore part 364 may be provided by mass 374.

Fore part 364 performs the functions discussed above with reference to aspear by integrating the target retainer and tip in the structure offore part 364. Fore part 364 may include an integral shaft to positiontip 378 a suitable distance in front of a face of fore part 364. Forepart 364 may omit the shaft structure of the spear as discussed above.

According to various aspects of the present invention, an electrode 142of FIG. 3C may be assembled by combining aft part 362 and fore part 364on an axis. For example, when x-filament retainer 370 has a first axisand y-filament retainer 372 has a second axis, these retainers may bealigned to an alignment axis and then moved together along the alignmentaxis to accomplish assembly of the two parts.

Electrode 142 of FIGS. 3A, 3B, and 3C may be implemented to providespreading. For example, an end of filament 140 may be positioned at ornear a front face of electrode 142. Either or both parts of eachelectrode design may support propagation of electricity from thefilament to the target. For example, either or both parts may comprisenon-insulative materials (e.g., conductive, resistive, insulative,composite).

Electrode 142 of FIGS. 3A, 3B, and 3C may be implemented to providediffusing. For example, material forming a front face, spear, targetretainer, and/or tip may comprise non-insulative materials.

An electronic weapon 100, according to various aspects of the presentinvention, may launch two electrodes each of any type discussed hereinwith reference to electrode 142, where one electrode serves in thereturn path, as discussed above. For example, electronic weapon 100 ofFIG. 4 is shown immediately after a user initiated launch of twoelectrodes from a deployment unit. Electronic weapon 100 includes ahand-held launch device 110 that receives and operates onefield-replaceable cartridge 130 as a type of deployment unit. Launchdevice 110 houses a power supply (having a replaceable battery), aprocessing circuit, and a signal generator as discussed above. Launchdevice 110 may be of the type known as a model M26 electronic controldevice marketed by TASER International, Inc. Cartridge 130 includes aplurality 402 of tethered electrodes including electrodes 142 and 143.Upon operation of trigger 401, electrodes 142 and 143 are propelled fromcartridge 130 generally in direction of flight “A” toward a target (notshown). As electrodes 142 and 143 fly toward the target, electrodes 142and 143 deploy behind them filaments 140 and 441 respectively. Whenelectrodes 142 and 143 are positioned in or near the target, filaments140 and 441 extend from cartridge 130 to electrodes 142 and 143respectively. The signal generator provides a stimulus signal throughthe circuit formed by filament 140, electrode 142, target tissue,electrode 143, and filament 441. Electrodes 142 and 143 mechanically andelectrically couple to tissue of the target as discussed above.

A deployment unit may substantially simultaneously deploy a plurality ofelectrodes. For example, deployment unit 130 of FIG. 5 includes theexterior dimensions, features, and operational functions, of aconventional cartridge of the type used with model M26 and X26electronic control devices marketed by TASER International, Inc. FIG. 5is drawn to scale with the angle formed by the launch tubes being 8degrees. For deployment unit 130, two electrodes are simultaneouslypropelled from respective cylindrical launch tubes (e.g., bore, chamber)in a housing of the deployment unit. For example, deployment unit 130includes housing 502, cover 508, filament storage (not shown), bores 504and 506, propellant system 144, 145 comprising several components, andtethered electrodes 142 and 143. Each tethered electrode 142 (143) ismechanically coupled to a respective filament (one shown) 141, to deploythe filament with the electrode. Spaces for filament storage are locatedon both sides of the plane of the bores of the housing, so that in thecross-section view of FIG. 5, one storage space is removed by crosssection and the other is hidden. In use, the propellant explosivelyprovides a volume of gas that pushes each electrode 142 (143) from therespective bore 504 (506). Acceleration, muzzle velocity, flightdynamics, and accuracy of hitting the target are affected by the fit ofthe electrode as it leaves the bore. Any diameter along the length ofthe electrode that exceeds a limit interferes for a period of timeunnecessarily with propelling the electrode from the bore.

Portions and/or parts of an electrode, as discussed above, may beformed, according to various aspects of the present invention, ofmaterials that are not highly conductive. These materials are discussedabove as resistive, insulative, and composite. The structure of thesematerials may be uniform through a volume or nonuniform. When uniform,electrical activation may be in accordance with a resistance per unitlength and one or more lengths of conduction (path lengths) needed toaccomplish suitable activation. Nonuniformity may be accomplished byvarying the blend of constituents of the material when molding thedesired structure, or by arranging materials of different properties inseries assembly. Nonuniformity may cause resistance to increase awayfrom the target or to any desired nonlinear extent. Conductive and/orresistive materials may be combined with insulative materials in anyconventional fashion.

Insulative materials include nonconductors. When exposed to ionizationvoltages, portions of insulative materials along paths of ionization mayreform (e.g., wear, deform, mobilize, melt, vaporize, temper, congeal,crystallize, stratify, reconstitute) into resistive materials, voids,and/or pockets of component materials (e.g., liquids or gases). Reformedinsulative materials are examples of resistive or non-insulativematerials. Reformation may change a magnitude of voltage needed for adesired activation. Insulative materials may comprise plastic, nylon,fiberglass, or ceramic. Insulative coatings include lacquer, black zinc,a dielectric film, a non-conductive passivation layer, a polyp-xylylenepolymer (e.g., Parylene), polytetrafluoroethylene (e.g., Teflon), athermoplastic polyamide (e.g., Zytel). Conventional insulativetechnologies may be used.

Insulative materials of a type herein called composite materials mayinclude separated conductors. Conventional composite materials aremanufactured and used for molding and overmolding. For example, acomposite material may be formed from a liquid resin, plastic, orthermoplastic as a host material with solid fibers, spheres, ellipsoids,powder, or other particles as filler mixed into the host before the hostcures to a solid. Host material may be plastic, nylon, PEEK(polyetheretherkeytone), thermoplastic elastomer (e.g., thermoplasticpolyurethane (TPU)), SBS poly(styrene-butadiene-styrene) rubber.Particles of conductive (e.g., metal, stainless steel, tungsten) orresistive (e.g., carbon) material may be used as filler. Particleshaving a coating of conductive or resistive material may be used asfiller. For example, insulative material of the type marketed by RTP Co.as thermoplastic polyurethane elastomer (TPUR/TPU) comprisingnickel-coated carbon fiber may be used. Spheres or powder may have adiameter of from about 3 to about 11 microns. Fibers may have a similardiameter and a length of from about 5 to about 7 millimeters. Filler tohost by weight may be from about 5% to about 40% to assure separation(nonoverlap) of particles. Composition may result in activation voltagesof from about 50 volts to about 6000 volts for components of electrodes142. In operation at voltages expected to be sufficient for ionizationbetween nonoverlapping particles, composite materials are also examplesof non-insulative material.

A tethered electrode 600, of FIGS. 6 and 7, in accordance with thefunctions discussed above with reference to FIGS. 1, 2, 3A, 4, and 5,retains a filament 601 in an assembly of a carrying part 602 andpiercing part 604. Electrode 600 is substantially cylindrical as shownin the rear view of surface 620 in FIG. 7. Carrying part 602 includes anx-fastener (surface 622) and a filament positioner (notch 612).Retention of filament 601 is accomplished by the cooperation of carryingpart 602 and piercing part 604. Piercing part includes a y-fastener(surface 624), a filament retainer (bore 702), a shaft positioner (twonotches 630), and a spear 640 having an elbow 634, a shaft 608, a targetretainer (barb 613), and a tip 614. A filament positioner is omittedfrom piercing part 604.

Carrying part 602 includes a cylindrical outer surface 642 and a conicalinner surface 644 so as to accept piercing part 604. Piercing part 604has a substantially conical outer surface 652 and a substantiallycentral bore 702.

When unassembled, slot 704 opens to accept spear 610 and filament 601.Spear 610 may be positioned for one of two lengths measured from frontface 611 of electrode 600 to tip 614. For a first length, as shown,elbow 634 of shaft 608 is located over notch 632 so that a portion ofshaft 608 extends into notch 632. For a second longer length, elbow 634is located over notch 633 and is retained in piercing part 604 in a wayanalogous to the configuration of the first length. Filament 601 is thenplaced in bore 702 in abutting contact along a rear portion of shaft608. Filament 601 is extended past front face 611 and toward notch 612.A portion of filament 601 may be uninsulated to facilitate electricalcoupling of filament 601 and target tissue with little or no need forionization. The uninsulated portion may include elbow 606 and furthermay include additional portions of filament 601 proximate to elbow 606.

To assemble electrode 600, carrying part 602 is threaded onto filament601 and set aside. An axial opening for access to bore 702 in piercingpart 604 is opened and shaft 608 is located in a suitable notch 630.Filament 601 is laid on top of shaft 608. Piercing part 604 is thencompressed circumferentially with respect to an axis of circularsymmetry to close the axial opening. Carrying part 602 is aligned on thesame axis as piercing part 604 and the two parts are pressed togetheruntil surface 622 of piercing part 602 snaps over and latches againstsurface 624 of carrying part 604. When assembled, a resistance to expandradially of carrying part 602 causes surfaces 644 and 652 to grip infriction fit against each other, to retain filament 601 in bore 702, andto retain elbow 634 over the selected notch of notches 630. The assemblyis held together by the mechanical interference of surfaces 622 and 624that form a fastener (e.g., latch, catch, snap).

Notch 612 may be dimensioned to retain filament 601 by friction fit.

Bore 702 may be dimensioned to retain filament 601 by friction fit inthe absence of carrying part 602 and/or when assembled with carryingpart 602 (e.g., bore 702 diameter reduced by radial pressure).

Another tethered electrode 800, of FIGS. 8 and 9, in accordance with thefunctions discussed above with reference to FIGS. 1, 2, 3B, 4, and 5,retains a filament 808 in a coaxial assembly of aft part 802 and forepart 804. Electrode 800 is substantially cylindrical as shown in theperspective views of FIGS. 8 and 9. Aft part 802 includes an x-fastener(tabs 832 and 834) and an x-filament retainer (notch 812). Fore part 804includes a y-fastener (tab 842 and a symmetrically arranged identicaltab not shown but diametrically opposite tab 842), a y-filament retainer(rear surface of fore part 804), and a spear 844 comprising a shaft 846,a target retainer 848, and a tip 850. Fore part 804 may be formed ofplastic or metal (e.g., brass, aluminum). Spear 844 may be formed of thesame material (e.g., cast, machined) or a dissimilar material (e.g.,stainless steel inserted into plastic rear portion).

In one implementation, shaft 846, target retainer 848, and tip 850 areformed of relatively more resistive or insulative (e.g. compositematerial) than the other portions of fore part 804 (e.g., activation atrelatively higher voltage).

When unassembled, bore 908 or FIG. 9 accepts filament 808. Filament 808is bent and pressed into channel 814 in face 906 of aft part 802.Channel 814 retains filament 808 by friction fit. Friction is increasedwhen fore part 804 abuts filament 808 when locked in assembled positionagainst aft part 802.

To assemble electrode 800, filament 808 is threaded into aft part 802and laid into channel 814. The, aft part 802 is aligned on a commoncylindrical axis with fore part 804, and the two parts are pushedtogether until the fasteners (tabs 832, 834, 842) fasten to each other.Four tabs interdigitate: 902 and 904 with tabs 842 and its symmetricalopposite tab (not shown). The assembly is held together by themechanical interference of the four tabs that form a fastener (e.g.,latch, catch, snap). The force to operate the fastener conforms filament808 to channel 814 and increases friction between filament 808 andabutting surfaces of the channel and fore part 804 to accomplish thefilament retaining function.

Another tethered electrode 1000, of FIGS. 10-14, in accordance with thefunctions discussed above with reference to FIGS. 1, 2, 3C, 4, and 5,retains a filament 140 in an assembly of aft part 1002 and fore part1004. Electrode 1000 is substantially cylindrical as shown in theperspective views of FIG. 10. Aft part 1002 includes an x-filamentretainer comprising a channel 1120 formed with two latch arms 1206 and1406. Fore part 1004 includes a y-filament retainer comprising base 1310having an irregular surface 1312 formed with anvil 1304 that cooperateswith latch arms 1206 and 1406. Fore part 1004 additionally includes amass 1102 with a surface 1010 for propagating stimulus current to thetarget, a front face 1012, a target retainer 1006 comprising a shaft1007, barb 1108, and tip 1008. Aft part 1002 may be formed of resilientmaterial (any relatively soft plastic). Fore part 1004 may be formed ofrigid material (e.g., any relatively hard plastic, composite material).

In the cross section view of FIG. 11 taken along an axis of circularsymmetry of electrode 1000, surfaces of filament retainer 1002 and forepart 1004 are shown cooperating to retain filament 140 by friction in achannel 1120 that proceeds symmetrically in two directions from opening1220. Filament 140 is forced to conform to surfaces defining channel1120 as aft part 1002 is fastened to fore part 1004. Mass 1102 isovermolded onto shaft 1104 of fore part 1004. Mass 1102 is formed ofresistive and/or composite material with an exposed surface 1010suitable for propagating current from an exposed end 1003 of filament140 toward front face 1012.

In the perspective rear view of assembled electrode 1000 of FIG. 12,filament 140 is shown threaded through opening 1220 with an exposed end1003 trimmed flush to electrode 1000 after assembly of aft part 1002 andfore part 1004. Exposed end 1003 is positioned within a suitabledistance for ionization to occur between exposed end 1003 and surface1010 for propagation of current as discussed above. Aft part 1002 isformed of resilient material (e.g., plastic). Aft part 1002 includeslatch arm 1206 and an identical second latch arm 1205 diametricallyopposite latch arm 1206. Latch arm 1206 includes an opening 1202 thatadmits anvil 1204 of fore part 1004. When aft part 1002 and fore part1004 are assembled, latch surface 1208 interferes with a forward surface(not shown) of anvil 1204 to retain aft part 1002 fixed to fore part1004. Identical features and cooperation occur with respect to thesecond latch arm 1205 and a second surface (not shown) of anvil 1204.

Filament 140 is retained in a channel 1120 as discussed above and asillustrated in FIGS. 13 and 14. Channel 1120 is defined across adiameter of the electrode that includes opening 1220 through whichfilament 140 enters channel 1120. Channel 1120 is defined by irregularsurface 1432 of aft part 1002 in cooperation with irregular surface 1312that traverses base 1310, and a respective inner surface of each ofbarriers 1422, 1424, 1426, and 1428 all of fore part 1004. Base 1310comprises the integral combination of a surface for retaining filament140 and surfaces for latching aft part 1002 with fore part 1004. Anvil1204 includes ends 1304 and 1305. Each latch arm 1206 (1406) is held bya surface (not shown) of anvil 1204 at an end 1304 (1305) of anvil 1204to maintain the assembly of aft part 1002 and fore part 1004.

A barrier, according to various aspects of the present invention,defines a channel, assures proper assembly, and includes an irregularsurface for retaining a filament. Aft part 1002 comprises four barriers1422, 1424, 1426, and 1428 that are symmetrical and arranged aboutopening 1220. Each barrier provides surfaces with structure andfunctions analogous to surfaces 1434 and 1436 of barrier 1422. Barriers1422 and 1424 define half channel 1420 of channel 1120. Filament 140 isshown in channel 1420 of FIG. 14. Filament 140 is retained in ananalogous manner when located in half channel 1421 of channel 1120.Surface 1436 guides either end 1304 or 1305 of anvil 1204 into properorientation for operation of latch arms 1206 and 1406. Surface 1434prohibits filament 140 from leaving half channel 1420. Consequently,when latch arms 1206 and 1406 catch on anvil 1204 as discussed above,filament 140 must conform to irregular surfaces 1432 and 1312. Latcharms 1206 and 1406 and anvil 1204 are dimensioned so that surfaces 1432and 1312 are separated by a distance suitable for retaining filament 140under all conditions of electrode 1000 use including assembly,deployment, and impact with a target.

EXAMPLES OF THE INVENTION

A deployment unit for an electronic control device (ECD) used as aweapon provides a current from a signal generator of the ECD throughtissue of a human or animal target. The deployment unit includes ahousing, an interface, a filament, and an electrode. The interfacecouples the housing to the signal generator. The filament includes afirst end coupled to the interface for receiving the current andcomprises a second end. The filament conducts the current for inhibitingvoluntary movement by the target. The electrode, stored in the housingprior to deployment, mechanically couples the filament to the targetwhen deployed. The electrode includes an assembly of a first part and asecond part that after assembly cooperate to bind the second end of thefilament to the electrode.

A method for manufacturing an electrode for use by an electronic weapon,the method comprising assembling a filament, a first part, and a secondpart by latching the first part with the second part thereby binding thefilament between the first part and the second part.

The foregoing description discusses preferred embodiments of the presentinvention, which may be changed or modified without departing from thescope of the present invention as defined in the claims. Examples listedin parentheses may be used in the alternative or in any practicalcombination. As used in the specification and claims, the words‘comprising’, ‘including’, and ‘having’ introduce an open endedstatement of component structures and/or functions. In the specificationand claims, the words ‘a’ and ‘an’ are used as indefinite articlesmeaning ‘one or more’. While for the sake of clarity of description,several specific embodiments of the invention have been described, thescope of the invention is intended to be measured by the claims as setforth below.

What is claimed is:
 1. An electrode for delivering a current throughtissue of a human or animal target to impede locomotion of the target, aprovided filament electrically couples the electrode to a providedsignal generator to provide the current, the electrode comprising: anaft part; and a fore part; wherein prior to assembly, the aft part isseparate from the fore part; the aft part mechanically couples to thefore part to form the electrode; the aft part and the fore part remainmechanically coupled after deployment of the electrode to deliver thecurrent; while the aft part is coupled to the fore part, the aft partcooperates with the fore part to bind an end portion to the filament tothe electrode, the electrode receives the current via the filament fordelivery through the target to impede locomotion of the target.
 2. Theelectrode of claim 1 wherein a surface of the aft part abuts a surfaceof the fore part to cooperate to bind the filament.
 3. The electrode ofclaim 1 wherein while the aft part is coupled to the fore part: the endportion of the filament is positioned between a first surface of the aftpart and a second surface of the fore part; and the first surface andthe second surface press on the end portion of the filament to bind thefilament to the electrode.
 4. The electrode of claim 1 wherein: the aftpart comprises a channel that receives the end portion of the filament;a surface of the fore part abuts the end portion of the filament to holdthe filament in the channel to bind the filament to the electrode.